Transmission synchronizer pin arrangement

ABSTRACT

A plurality of pins couple the cones and the shift collar of a transmission auxiliary section together so that they rotate as a group. When the shift collar is moved laterally from neutral, the shift collar engages blocking surfaces on the pins and moves the corresponding cone to match the speeds of the input shaft and the corresponding gear. The invention shortens the pin lengths of the synchronizer and therefore the length of the transmission, by eliminating contact between the shift collar and the small diameters of the pins in the neutral position.

RELATED APPLICATIONS

This application is a divisional of application Ser. No. 09/235,180filed Jan. 22, 1999, now U.S. Pat. No. 6,390,266.

BACKGROUND OF THE INVENTION

This invention relates to pin arrangements used in cone synchronizers tofacilitate shifting between high and low ranges in a multispeedtransmission.

In the prior art, heavy vehicle transmissions typically consist of twosections. A first main section includes a plurality of selectable gearsto provide different speed ratios. A second auxiliary section takes aninput from the first section and modifies the speed to provide amultiple of additional speeds. Auxiliary sections include both range andsplitter sections.

The range section shifts the speeds within the main transmission sectionbetween two ranges, namely high and low. The background will beexplained with reference to a range section, but it should be understoodit may also apply to splitter sections. Known range sections move ashift collar to connect an input shaft directly to an output shaft,thereby creating a high speed. Alternatively, the collar connects theinput to a gear reduction to drive the output shaft to provide the lowfunction.

A synchronizer may be associated with both the high and low rangepositions to assist the transmission in beginning to move the gears tothe desired speed just prior to engagement. The synchronizer includes afirst and second cone in spaced relationship with the shift collarinterposed between. A plurality of pins couple the cones and the shiftcollar together so that they rotate as a group. When the shift collar ismoved laterally from neutral into high or low range, the shift collarengages blocking surfaces on the pins and moves the corresponding coneto match the speeds of the input shaft and the corresponding gear.

Since pin length determines, in part, the length of the synchronizer andtherefore the length of the transmission, it is desirable to utilize theshortest pin length possible. FIG. 1A depicts a prior art configurationutilizing preblocked pins 2, 4 while FIG. 1B depicts a prior artconfiguration utilizing preenergized pins 15. Reference will now be madeto both the preblocked synchronizers and preenergized synchronizerssimultaneously with preenergized synchronizer reference numerals inparentheses. These prior art configurations require that during a shiftfrom one range to another (for example from left to right in theFigures), the shift collar disengages the large diameter surfaces 6(16), then engages the small diameter surfaces 8, 12 (18), and engagesthe blocking surfaces 13 (19) thereby causing the cone 66 (66) to moveto the right to synchronize a gear. Once synchronized, the shift collarengages the large diameter surfaces 11 (16).

Similarly, when a shift is made from right to left, the shift collardisengages the large diameter surfaces 11 (16), then engages the smalldiameter surfaces 8, 12 (18), and engages the blocking surfaces 10 (19)thereby causing cone 42 (42) to move to the right to synchronize a gear.Once synchronized the shift collar engages the large diameter surfaces 6(16).

By eliminating engagement of the shift collar with the small diametersurfaces in the neutral position between range shifts, the overall pinlength may be reduced thereby reducing the length of the synchronizerand transmission.

SUMMARY OF THE INVENTION

In a preferred embodiment of this invention, a plural cone synchronizeris incorporated into an auxiliary section of a heavy vehicletransmission. First and second cones are in spaced relationship from oneanother and rotate about a common axis. A shift collar is interposedbetween the first and second cones and rotates about and is slidablealong the axis to and from a neutral position. The shift collar hasfirst and second sets of apertures therethrough which have engagingsurfaces.

A plurality of preblocked pins interconnect the first and second cones.A first set of pins extend from the first cone through the first set ofapertures. The first set of pins have first large diameter surfacesadjacent to the first cone and first small diameter surfaces oppositethe first large diameter surfaces. First blocking surfaces are disposedbetween the first small and large diameter surfaces. Similarly, a secondset of pins extend from the second cone through the second set ofapertures. The second set of pins have second large diameter surfacesadjacent to the second cone and second small diameter surfaces oppositethe second large diameter surfaces. Second blocking surfaces aredisposed between the second small and large diameter surfaces.

The pins collectively have neutral surfaces that are engageable with theengaging surfaces when the shift collar is in the neutral position. Theengaging surfaces are prevented from simultaneously engaging with thefirst and second small diameter surfaces in the neutral position becauseof the width of the engaging surfaces and the location of the first andsecond blocking surfaces relative to one another. In this way, thecontact with the small diameters is eliminated when shifting betweenhigh and low range.

A method of shifting between a plurality of gears using the abovepreferred pin arrangement includes decoupling a first gear and a shiftby moving a synchronizer shift collar out of engagement with a set offirst large diameter pin surfaces. The next step includes synchronizinga second gear and the shaft by moving the shift collar into engagementwith a set of second blocking pin surfaces. Finally, the last stepincludes coupling the second gear and the shaft by moving the shiftcollar into engagement with a set of second large diameter pin surfaces.

These and other features of the present invention can be best understoodfrom the following specification and drawings, of which the following isa brief description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a potential cross-sectional view through a prior artsynchronizer having preblocked pins;

FIG. 1B is a partial cross-sectional view of an alternative prior artsynchronizer having preenergized pins;

FIG. 2 is a cross-sectional view through the inventive synchronizer withthe range section in the neutral position prior to upshifting into highrange;

FIG. 3 is a cross-sectional view along line 3—3 as shown in FIG. 2;

FIG. 4 is a cross-sectional view similar to FIG. 2 with the rangesection in high range;

FIG. 5 is a cross-sectional view along line 5—5 as shown in FIG. 4;

FIG. 6 is a cross-sectional view similar to FIG. 2 with the rangesection in the neutral position prior to downshifting into low range;

FIG. 7 is a cross-sectional view along line 7—7 as shown in FIG. 6;

FIG. 8 is a cross-sectional view similar to FIG. 2 with the rangesection in low range;

FIG. 9 is a cross-sectional view along line 9—9 as shown in FIG. 8;

FIG. 10 is a cross-sectional view of an alternative embodiment of thepresent invention using preenergized pins; and

FIG. 11 is a cross-sectional view taken along line 11—11 as shown inFIG. 9.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Heavy vehicle transmissions typically consist of two sections. Referringto FIG. 2, a first main section 23 includes a plurality of selectablegears to provide different speed ratios. A second auxiliary section 20takes an input from the first section and modifies the speed to providea multiple of additional speeds. Section 20 could be a range section, asplitter section, or a combination of the two. The invention will bedescribed with reference to a range section, but it should be understoodthat it has benefits in other types of auxiliary sections.

Range section 20 receives an input shaft 22 from a main transmissionsection 23. Input shaft 22 drives a gear 24 engaged with a countershaftgear 26. Countershaft gear 26 drives a countershaft 28 which, in turn,drives gear 31. Gear 31 is engaged with a gear 30 mounted on an outputshaft 32. The input shaft 22 is selectively connected either directly tooutput shaft 32 for high range, or through the gears 26. 31 and 30 tothe output shaft 32 to achieve a speed reduction and low range. A shiftcollar 34 achieves the selective connection. Shift collar 34 includes anengagement member 36 having internal teeth 37 which constantly engageteeth 40 on an output shaft 32.

The range section is shown in neutral with neither range engaged. In aposition where collar 34 is moved to the left from the illustratedposition, teeth 37 engage teeth 38 on gear 24. Rotation is thentransmitted directly from input shaft 22 to output shaft 32. Thisposition provides high range (FIG. 4).

When the transmission shifts to low range, collar 34 moves to the rightfrom the illustrated position and teeth 37 engage teeth 100 of gear 30.In this position, gear 30 is now driven with output shaft 32. Rotationis transmitted through the countershaft gears and to the output shaft32. There is a speed reduction provided by the gears 24, 26, 32 and 30which results in a lower speed for the output shaft 32. This positionprovides the low range (FIG. 8).

A synchronizer is associated with both the high and low range positionsto assist the transmission in beginning to move the gears to the desiredspeed just prior to engagement. The synchronizer has first 42 and second66 cones in spaced relationship from one another that are rotatableabout a common axis A. The first cone 42 is used for high range shiftingwhile the second cone 66 is used for low range shifting. The first cone42 is associated with the second cone 66 and a group of other low rangesynchronizer cones 72, 74 by a first set of preblocked pins 45. Thefirst set of pins 45 are affixed in bores 43 in the first cone 42. Thepins 45 extend through a first set of apertures 47 a in the shift collar34 and into slots 49 in second cone 66. In this manner, the pins 45couple the cones 42, 66 and the shift collar 34 so that they rotatetogether about axis A. The slots 49 permit slight relative movementbetween the cones 42, 66.

The first set of pins 45 have first large diameter surfaces 50 adjacentthe first cone 42 and first small diameter surfaces 52 opposite thefirst large diameter surfaces 50. Tapered first blocking surfaces 54 aredisposed between the first large 50 and small 52 diameter surfaces.Clips 56 on ends of the first small diameter surfaces 52 retain thesecond cone 66 to prevent the second cone 66 from engaging the cones 72,74 and inadvertently synchronizing the low range during a high rangesynchronization.

A second set of pins 46 extend from bores 48 in the second cone 66through a second set of apertures 47 b in the shift collar 34. Thesecond set of pins 46 have second large diameter surfaces 58 adjacentthe second cone 66 and second small diameter surfaces 60 opposite thesecond large diameter surfaces 58. Tapered second blocking surfaces 62are disposed between the second large 58 and small 60 diameter surfaces.The second pins 46 keep the first 42 and second 66 cones spaced apart byat least the distance from the surface of the cone 66 to the endfarthest from the second cone 66 on the small diameter surfaces 60.

The first 47 a and second 47 b sets of shift collar apertures haveengaging surfaces 64 a, 64 b on their inner periphery which engage theblocking surfaces 54, 62 and the large diameter surfaces 50, 58 of thefirst 45 and second 46 sets of pins in the neutral position betweenrange shifts. The shift collar apertures 47 a, 47 b include the taperedportions 70, 71 that mates with the blocking surfaces 54, 62 andincludes the portion 69, 73 parallel with the large diameter surfaces50, 58.

Referring now to FIG. 3, the shift collar 34 further includes bores 75with springs 76 for biasing the set of first pins 45. The bores 75 andsprings 76 do not pass through section line 3—3 but are offset. Bores 75and springs 76 are perpendicular to pin 45 and aligned with slots 49.The biasing springs 76 create a misalignment between the engagingsurfaces 64 a, 64 b and the pins 45, 46 so that as the shift collar 34is moved from neutral into a gear, the engaging surfaces 64 a, 64 b willbe forced to contact the blocking surfaces 54, 62. Otherwise, theengaging surfaces 64 a, 64 b may pass by the blocking surfaces 54, 62without applying force to the pins 45, 46 to move the cones 42, 66 andsynchronize the input shaft 22 and the gears.

The shift from neutral (FIG. 2) into high range (FIG. 4) is discussedbelow. During the shift, the first cone 42 is moved by firstsynchronizer pin 45 when the collar 34 is moved to the left to achievehigh range. The engaging surface 64 a engages the blocking surfaces 54on pins 45 and forces cone 42 to the left. A friction surface 200 formedon the inner periphery of cone 201 engages the synchronizer cone 42.Synchronizer cone 201 has splines 202 which engage mating splines 38 ongear 24. When the transmission is shifted to high range, thesynchronizer cones 42 and 201 engage before teeth 37 and 38 engage.Thus, the cones begin to move gear 24 and shaft 32 to equal speeds priorto engagement.

Upon engagement of the teeth 37, 38 the first small diameter surfacesmove within the slot 49 until the engaging surfaces 64 a are fullyengaged with the large diameter surfaces 50 of the first pins 45 therebycompressing the biasing springs 76, as shown in FIG. 5.

The pins 45, 46 collectively have neutral surfaces engageable with theengaging surfaces 64 a, 64 b when the shift collar 34 is in the neutralposition. That is, the neutral surfaces include any pin surfaces thatcontact the engaging surfaces 64 a, 64 b when the shift collar 34 is inthe neutral position. The engaging surfaces 64 a, 64 b are preventedfrom simultaneously engaging the first 52 and second 60 small diametersurfaces when the shift collar 34 is in the neutral position.

Said another way, the engaging surfaces 64 a, 64 b in the shift collar34 will not be aligned with the small diameters 52, 60 at any locationin the neutral position to where the engaging surfaces 64 a, 64 b couldfully contact either the first small diameter surfaces 52 or the secondsmall diameter surfaces 60 (see FIGS. 1 and 2). That is not to say,however, that the engaging surfaces 64 a, 64 b cannot be aligned with asmall portion of both the first 52 and second 60 small diameterssimultaneously.

Said yet another way, for the above shift sequence, in the prior art theengaging surfaces 64 b would be permitted to engage the second set ofsmall diameter surfaces 60 while the engaging surface 64 a was still inengagement with the first set of small diameter surfaces 52 before theengaging surface 64 a engaged the first blocking surfaces 54 and finallysynchronized the input shaft 22 and output shaft 32.

In contrast for the same shift sequence, the present invention pinarrangement eliminates contact between the engaging surface 64 b and thesecond small diameter surfaces 60 before the engaging surface 64 aengages the first small diameter surfaces 52. By eliminating theintermediate shift sequence of the prior art, the present inventionshortens the overall pin length by shortening the lengths of the smalldiameter surfaces 52, 60.

Referring now to FIG. 6, a position is depicted in which the shiftcollar is again in the neutral position but just prior to being shiftedinto low range. In this position the engaging surfaces 64 a are stillengaged with the first large diameter surfaces 50 while the engagingsurfaces 64 b re engaging the second blocking surfaces 62. However, theengaging surface 64 a does not have to fully disengage either the largediameter surfaces 50 or the blocking surfaces 54 before being shiftedinto low range. That is, the engaging surface 64 a does not have toengage the small diameter surfaces 52 before pin 46 engaging blockingsurfaces 62, as in the prior art.

FIG. 7 depicts the orientation of the pins 45, 46 relative to theengaging surfaces 64 a, 64 b.

During a low range shift, which occurs between the shift collar 34portion shown in FIG. 6 to FIG. 8, the collar 34 is moved to the rightto achieve low range. The engaging surface 64 b engages second blockingsurfaces 62 on the pins 64 and forces cone 66 to the right whichinteracts with cones 72 and 74 to synchronize the low range as discussedin more detail below.

FIG. 9 depicts the orientation of the pins 45, 46 relative to theengaging surfaces 64 a, 64 b.

Cone 66 has spaced outer surfaces 68 with intermediate gaps whichreceive tab 70 from an outer synchronizer cone 72. A middle synchronizercone 74 has a radially inwardly extending portion 75 extending to aseries of splines 76 received in teeth 100 on the gear 30. Thus, themiddle synchronizer cone 74 tends to rotate with the gear 30, and as thecollar 34 is shifted to the right, the frictional interaction betweencones 66 and 74, 74 and 72 and 72 and gear 30 through the frictionsurfaces 80, 78 and 79, tend to move the cones 66 and 72 rapidly up tothe same speed as the cone 74 and gear 30. Tabs 70 extend between andinto gaps between sections 68 of cone 66 to ensure that the outer andinner cones rotate together. The teeth 100 are engaged by the teeth 76of the middle cone. Thus, gear 30 tends to quickly reach the same speedas shaft 32. Again, the cones begin to drive the gear to thesynchronized speed prior to teeth 37 engaging teeth 100.

An alternative embodiment of the present invention utilizingpreenergized pins 84 is shown in FIGS. 10 and 11. Instead of using twosets of pins 45, 46 like preblocked synchronizers 20, preenergizedsynchronizers 82 use only one set of pins 84. Preenergized synchronizers82 operate on the same principle as preblocked synchronizers 20, thatis, a biasing spring 17 c engages a portion on the pins 84 to blockcontact of spline 37 with spline 38 or spline 100 prior tosynchronization.

The pins 84 interconnect the cone 42, 66 together and extend throughapertures 17 c that have engaging surfaces 64 c on collar 34. The pins84 have small diameter surfaces 86 adjacent to the first and secondcones 42, 66. Each pin 84 includes a large diameter surface 88 havingopposing sides with first 90 and second 92 blocking surfaces positionedon each of the sides of the large diameter surfaces 88 respectively. Thelarge diameter surfaces 88 arc positioned substantially centrally alongthe small diameter surfaces 86 so that the large diameter surface 88 isdisposed within the aperture 47 c when the shift collar is in theneutral position, as shown in FIG. 10.

During a shift from high to low gear (left to right in FIG. 10), theengaging surface 64 c engages the first blocking surface 90 when theshift collar decouples the input 22 and output 32 shafts which forcesthe pins 81 to the right thereby causing cone 66 to synchronize theoutput shaft 32 and reduction gear 30. Once the speeds of the outputshaft 32 and reduction gear 30 sufficiently match, the shaft 32 and gear30 may be coupled together.

Similarly, when shifting from low to high gear (right to left in FIG.10), the engaging surface 64 c engages the second blocking surface 92when the shift collar decouples the output shaft 32 and the reductiongear 30. This in turn forces pins 84 to the left thereby causing cone 42to synchronize the input shaft 22 and the output shaft 32. Once thespeeds of the shafts 22, 32 sufficiently match, the shift collar 34 maycouple the shafts 22, 32 together.

The preenergized pins 84 of the present invention rearranges theposition of the blocking surfaces, or swaps positions of the blockingsurfaces of the prior art (FIG. 1B), so that the clutch collar willengage the blocking surface associated with the gear to be engagedimmediately after disengaging from a gear.

Again, while the disclosed synchronizers are shown in a range section,they could be used in a splitter section or a combined range/splittersection.

Although preferred embodiments have been disclosed, a worker in this artwould recognize that certain modifications come within the scope of thisinvention. Thus, the following claims should be studied to determine thetrue scope of this invention.

What is claimed is:
 1. A multispeed transmission having a synchronizercomprising: first and second cones in spaced relationship from oneanother and rotatable about a common axis; a shift collar interposedbetween said first and second cones and rotatable about and slidablealong said axis to and from a neutral position, said shift collar havingapertures therethrough with engaging surfaces; a set of pins extendingfrom said first cone through said apertures, said set of pins havingsmall diameter surfaces adjacent said first and second cones and largediameter surfaces having opposing sides and positioned substantiallycentrally along said small diameter surfaces, and first and secondblocking surfaces positioned on each of said sides of said largediameter surfaces respectively; and said engaging surfaces beingengageable with said first blocking surface and sliding said second conebefore engaging said second blocking surfaces, and said engagingsurfaces being engageable with said second blocking surfaces and slidingsaid first cone before engaging said first blocking surfaces.
 2. Thetransmission as set forth in claim 1 further including first and secondgear positions wherein said shift collar is slidable therebetween withsaid neutral position interposed therebetween, said engaging surfaces ofsaid apertures engages said first blocking surfaces and subsequentlyengages said large diameter surfaces when said shift collar slides fromsaid neutral position to said first gear position.
 3. The transmissionas set forth in claim 2 wherein said engaging surfaces of said aperturesengages said second blocking surfaces and subsequently engages saidlarge diameter surfaces when said shift collar slides from said neutralposition to said second gear position.
 4. A method of shifting between aplurality of gears comprising: (a) decoupling a first gear and a shaftby moving a synchronizer shift collar out of engagement with the firstgear; (b) synchronizing a second gear and the shaft by moving the shiftcollar into engagement with second blocking pin surfaces; (c) moving theshift collar into engagement with large diameter pin surfaces; and (d)coupling the second gear and the shaft by moving the shift collar intoengagement with the second gear after disengaging the large diameter pinsurfaces.
 5. The method as set forth in claim 4 further comprising: (e)decoupling the second gear and the shaft by moving the shift collar outof engagement with the second gear; (f) synchronizing the first gear andthe shaft by moving the shift collar into engagement with a set of firstblocking pin surfaces; (g) moving the shift collar into engagement withthe large diameter pin surface; and (h) coupling the first gear and theshaft by moving the shift collar into engagement with the first gearafter disengaging the large diameter pin surfaces.